Oldham DL9, DL16 Instruction Manual And User Handbook
1
WARNING
This manual, including the warnings and cautions inside, must be read and followed carefully by all
persons who use or maintain this product, including those who have any responsibility involving its
selection, application, service, or repair.
This cap lamp system will perform as designed only if used and maintained according to the
instructions, otherwise it could fail to perform as designed and persons who rely on this product could
sustain serious personal injury or death.
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6
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CAP LAM
P SYSTE
M
INSTRUCTION
MANUAL
NO COMPROMISE
DL9:
Epsilon07ATEX2151/2: Ex I M2 Ex I IEC62013-1 Ta = 0
o
C to +40oC
DL16: Epsilon07ATEX2151/2: Ex I M2 Ex I IEC62013-1 Ta = 0
o
C to +40oC
IECEx ITS 08.0019: Ex I Ta = 0
o
C to +40oC
2
DDLL99 // DDLL1166 CCAAPP LLAAMMPP SSYYSSTTEEMM
TABLE OF CONTENTS
Important p3
General description p3
Preparation for use p3
Battery charging p3
Cap lamp system p4
Battery Storage p4
Replacing battery p4
Removing cable from battery p4
Replacing battery cover p4
Using DL9/DL16 cap lamp systems p4
Repairing headpiece p4
Replacing cable p5
Replacing reflector p5
Replacing circuit board p5
Reassembling bezel ring p6
Replacing the lock barrel p6
DL9/DL16 diagram – Item list p7
Parts diagram p8
Troubleshooting p9
Certification, equipment marking and instructions for p10
compliance with ATEX standards:-
Use of Equipment p11
Special Conditions for Safe Use p11
3
IMPORTANT
Pay close attention to Warnings and Cautions in
this manual.
A WARNING describes a condition that may
cause severe personal injury or death if allowed to
happen.
A CAUTION describes a condition that may cause
moderate injury or property damage if allowed to
happen.
GENERAL DESCRIPTION
The DL cap lamp systems consists of a cap
mounted headpiece powered by a Li Ion battery.
The basis of the headpiece in which some of the
internal connections are integral is as follows:
A selector switch is incorporated, which can
switch on either the main LED light source or the
small emergency LED. The reflector fits over the
small LED and has a rubber gasket around the
rim to seal against the headpiece lens.
PREPARING THE DL9/DL16 CAP LAMP FOR
FIRST TIME USE
The battery is packaged separately to the lamptop
and needs to be connected before use.
Tool kit required is M614830
NOTE: THE BATTERY IS TRANSPORTED IN A
PARTIALLY CHARGED CONDITION - EVERY
BATTERY MUST BE FULLY CHARGED
BEFORE FIRST USE.
Remove the battery from the shipping box and
check for damage. The battery is supplied with
the encapsulated fuse fitted, terminal nuts and
washers.
Remove the nut and washer from the positive end
of the fuse (marked +). Place the ring terminal of
the red wire onto the terminal post, replace the
spring washer and nut, and tighten to 0.5Nm.
Remove the nut and washer from the negative
terminal (not connected to the fuse) and place the
ring terminal of the black wire onto the terminal
post, replace the spring washer and nut, and
tighten down to 0.5Nm.
Hook the cable exit end of the battery cover onto
the battery.
Check that the cables are not trapped under the
edge of the cover then press down into position.
Secure the cover in place with the clip and M4
mushroom head socket screw.
Battery charging
WARNING
Li Ion batteries must only be charged on a
specific charger with a Li Ion charge profile. If
the battery is charged on a standard GT
caplamp charger the battery will be damaged.
For charger information and how to convert
existing charger software please consult the
Caplamp Charger Manual.
Every battery must be charged before it is used
for the first time.
Never discharge completely!
IMPORTANT NOTE:
The L16 battery is supplied with a factory fitted
“OCBL-T” fuse (M455323), required for
protection of the internal battery circuitry.
Use of any other fuse type could result in
damage and will invalidate any warranty claim.
4
Charging before first use:
1. Allow the battery to remain on charge for 24
hours.
2. After a working shift, the battery should be
placed on the charger, following the
instructions included with the charger, and left
to charge. The charger automatically
switches off when the battery is completely
charged
3. If cap lamp needs cleaning, use a mild
detergent and wipe. Do not submerge in
water.
Battery Storage
All stored batteries should be given a 24-hour
boost charge 3 months after receipt and thereafter
at 6-monthly intervals until use, where they should
again be fully charged before being placed into
regular service.
Recommended storage temperature: 0oC to 27oC.
Replacing battery
1. Remove one M4 button head socket screw
from the end clamp holding the cover as
shown.
2. Un-clip the clamp and slide off the cover to
cable end.
3. Remove the positive cable lead (red)
4. Remove the fuse
5. Remove the negative lead (black)
Replacing battery cover
1. Replace the fuse; fit the nuts to hold the fuse
in place
2. Connect the red cable to the positive battery
terminal.
3. Connect the black cable to the negative
battery terminal to ensure correct polarity.
4. Tighten the cable leads down with terminal
nuts to 0.5Nm.
5. Replace the battery cover.
Note:
Ensure that the cable leads lie properly on the
battery top without being trapped or pinched.
USING THE DL9/DL16 CAP LAMP SYSTEM
The DL headpiece is made up of the lamphousing which contains the following parts:
- Bezel (ring)
- Lens (glass)
- Gasket
- Reflector
- Main LED
- Secondary LED
- Circuit board and switch
The on-off-on switch knob is located on the
headpiece. The down position operates the main
LED and up position the secondary LED.
Repairing the headpiece
TOOLS:
G & D type spares and tools kit – M614830
D type Headpiece fastening & cable lock kit M259683
The switch should be placed in the off position
and the battery fuse removed (see section “cap
lamp system”) before disassembly of the
headpiece.
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